Process of making particle board from pyrophosphate treated polyisocyanates

ABSTRACT

A process is disclosed for the preparation of liquid, storage-stable, polyisocyanate compositions containing a release agent formed in situ which compositions are useful, for example, as binder resins in the formation of particle boards which latter, because of the presence of the release agent, show no tendency to adhere to the face of metal platens used in their formation. The process comprises heating an organic polyisocyanate (polymethylene polyphenyl polyisocyanate preferred) with an acid phosphate (e.g. a mixture of mono- and di-alkyl acid phosphates) under conditions controlled as to time and temperature so as to yield a product which is storage stable and shows no tendency to deposit solid or to separate into two liquid phases.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to polyisocyanate compositions and is moreparticularly concerned with storage stable liquid polyisocyanatecompositions containing a release agent formed in situ, and with amethod for the preparation of said compositions.

2. Description of the Prior Art

The use is known of organic polyisocyanates as binders, or as componentsof a binder, for the preparation of particle boards; see, for example,U.S. Pat. Nos. 3,428,592; 3,440,189; 3,557,263; 3,636,199; 3,870,665;3,919,017 and 3,930,110.

In a typical process the binder resins, optionally in the form of asolution or aqueous suspension or emulsion, are applied to or admixedwith particles of cellulosic or like material capable of beingcompressed into particle board, using a tumbler apparatus or blender orother form of agitator. The mixture of particles and binder is thenformed into a mat and subjected to heat and pressure using heatedplatens. The process can be carried out in a batch operation orcontinuously. To avoid adhesion of the board so formed to the heatedplatens it has hitherto been necessary to interpose a sheet, impermeableto isocyanate, between the surface of the board and the platen duringthe forming process, or to coat the surface of the platen, prior to eachmolding operation, with an appropriate release agent or to coat thesurface of the particles themselves with a material which will notadhere to the platen. Any of these alternatives, particularly where theprocess is being operated on a continuous basis, is cumbersome and adrawback to what is otherwise a very satisfactory method of making aparticle board with highly attractive structural strength properties.

It has recently been found that the above drawbacks to the use oforganic isocyanates as particle board binders can be overcome in a verysatisfactory manner by incorporating certain phosphorus-containingcompounds as internal release agents. These findings are disclosed incopending application Ser. No. 35,647 filed May 3, 1979 .Iadd.abandoned,and in application Ser. No. 134,315, filed Mar. 26, 1980 as acontinuation-in-part of said Ser. No. 35,647 and issued as U.S. Pat. No.4,257,995.Iaddend.. Among the phosphorus-containing compounds which canbe employed in accordance with the above findings are pyrophosphatesderived from mono- and di-hydrocarbyl acid phosphates and relatedcompounds. In accordance with the process described in the aforesaidpending application Ser. No. 35,647 the said pyrophosphates can beprepared separately by reacting the corresponding acid phosphates withdehydrating agents such as phosgene, phosphorus oxychloride and the likeand, if desired, can then be mixed with the polyisocyanate for use inthe formation of the particle boards. Alternatively, it is alsodisclosed in the aforesaid pending application that said pyrophosphatescan be prepared by reaction with the dehydrating agent in the presenceof the organic polyisocyanate.

We have now found that, by using very carefully controlled conditions,it is possible to prepare said pyrophosphates and related polyphosphatesin situ in said organic polyisocyanates without the use of additionalreagents such as the ecologically and toxicologically undesirablecompounds phosgene, phosphorus oxychloride, and the like. We havefurther found that it is possible to prepare organic polyisocyanateswhich contain said pyrophosphates and related polyphosphates produced insitu and which possess the additional desirable characteristics of beingliquid and storage-stable, i.e. they show no tendency to deposit solidsor to separate into two liquid phases on storage for prolonged periodsof time. This is in direct contrast to the behaviour of compositionsmade in a closely related manner but not observing the specific reactionconditions which are discussed in detail hereafter.

The ability to produce such liquid, storage-stable, polyisocyanatecompositions greatly facilitates the utilization of polyisocyanates asparticle board binders. Thus, it is possible thereby to provide theparticle board manufacturer with a single composition, prepared in ahighly economical manner, which can be utilized readily by themanufacturer in accordance with the process of the aforesaid Ser. No.35,647. The polyisocyanate compositions prepared in accordance with thisinvention can be applied, either as such or as an aqueous emulsion orsuspension, to the cellulosic or like particles which are subsequentlymolded, using heat and pressure, into particle boards. The latter, byreason of the pyrophosphate produced in situ in the compositions of theinvention, release readily from the mold platens.

SUMMARY OF THE INVENTION

This invention comprises a process for preparing a liquid,storage-stable, polyisocyanate composition containing a mold releaseagent formed in situ, which process comprises heating, at a temperaturein the range of about 60° C. to about 190° C., a mixture of an organicpolyisocyanate and from about 1 to about 20 parts, per 100 parts byweight of said polyisocyanate, of an acid phosphate selected from theclass consisting of acid phosphates having the formulae: ##STR1## andmixtures of two or more of said acid phosphates, wherein, in the aboveformulae, each R is independently selected from the class consisting ofalkyl having at least 3 carbon atoms, alkenyl having at least 3 carbonatoms, aryl, aryl substituted by at least one alkyl group, alkylsubstituted by at least one acyloxy group, wherein the acyl group is theresidue of an aliphatic monocarboxylic acid having at least 2 carbonatoms, and ##STR2## wherein R₁ is selected from the group consisting ofalkyl, aryl, and aryl substituted by at least one alkyl, one of A and Brepresents hydrogen and the other is selected from the class consistingof hydrogen, methyl, and chloromethyl and 2,2,2-trichloroethyl; X ischalcogen selected from the class consisting of oxygen and sulfur; and mis a number having an average value of 1 to 25;

the said heating of said mixture being carried out for a time such thatno phase separation occurs upon cooling the reaction mixture to anambient temperature.

The invention also comprises the liquid, storage-stable, polyisocyanatecompositions produced by the process set forth above as well as the useof said compositions as binders in the preparation of particle boardsand like materials.

The term "alkyl having at least 3 carbon atoms" means a saturatedmonovalent aliphatic radical, straight chain or branched chain, whichhas the stated minimum number of carbon atoms in the molecule.Illustrative of such groups are propyl, butyl, pentyl, hexyl, heptyl,octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl,hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl,docosyl, tricosyl, pentacosyl, hexacosyl, heptacosyl, octacosyl,nonacosyl, triacontyl, pentatriacontyl, and the like, including isomericforms thereof. The term "alkyl" when used without the above carbon atomlimitation is also inclusive of methyl and ethyl.

The term "alkenyl having at least 3 carbon atoms" means a monovalentstraight or branched chain aliphatic radical containing at least onedouble bond, and having the stated minimum number of carbon atoms in themolecule. Illustrative of such groups are allyl, butenyl, pentenyl,hexenyl, heptenyl, octenyl, nonenyl, decenyl, undecenyl, dodecenyl,tridecenyl, tetradecenyl, pentadecenyl, hexadecenyl, heptadecenyl,octadecenyl, nonadecenyl, eicosenyl, heneicosenyl, docosenyl,tricosenyl, pentacosenyl, triacontenyl, pentatriacontenyl, and the like,including isomeric forms thereof.

The term "aryl" means the monovalent radical obtained by removing onenuclear hydrogen atom from an aromatic hydrocarbon. Illustrative of arylare phenyl, naphthyl, biphenylyl, triphenylyl and the like. The term"aryl substituted by at least one alkyl" means an aryl radical, as abovedefined, carrying at least one alkyl (as above defined) substituent.Illustrative of such are tolyl, xylyl, butylphenyl, octylphenyl,nonylphenyl, decylphenyl, decyltolyl, octadecylphenyl and the like.

The term "aliphatic monocarboxylic acid having at least 2 carbon atoms"is inclusive of any alkanoic or alkenoic acid having the stated minimumnumber of carbon atoms. Illustrative of such acids are acetic,propionic, butyric, hexanoic, octanoic, lauric, stearic, oleic,undecylenic, dodecylenic, isocrotonic, palmitic, and the like.

Each of the groups R and R₁ in the formulae (I) and (II) set forth abovecan optionally be substituted by one or more inert substituents, i.e.substituents which do not contain active hydrogen atoms and which aretherefore unreactive in the presence of the polyisocyanate. Illustrativeof such inert substituents are alkoxy, alkylmercapto, alkenyloxy,alkenylmercapto, chloro, bromo, iodo, fluoro, cyano and the like.

DETAILED DESCRIPTION OF THE INVENTION

We have found that it is possible to convert acid phosphates, having theformula (I) and (II) above, to a product containing the correspondingpyrophosphates by heating said acid phosphates in the presence of anorganic polyisocyanate without the need to utilize any other reactantsuch as phosphorus oxychloride, phosgene, and the like. We have alsofound, however, that the reaction will give rise to a useful product,namely one which is a homogeneous liquid and which can be stored forprolonged periods without any tendency to undergo phase separation, onlyif the conditions of heating are carefully controlled.

The fact that there are any conditions at all which could lead to theformation of such a useful product is itself to be considered assurprising to one skilled in the art. Thus, the reaction of an acidphosphate of the type shown in formulae (I) and (II) with an organicisocyanate would be expected to proceed in accordance with the followingequation in which R has the significance defined above and R' representsthe residue of the organic isocyanate, which latter is shown asmonomeric for the sake of simplicity: ##STR3## The reaction results inthe formation of the desired pyrophosphate in association with somepolyphosphate. The reaction also gives rise to the intermediateformation of the amine (IV) corresponding to the starting isocyanate.The amine (IV) would react immediately with additional isocyanate toform a urea. In the case of the use of a polyisocyanate the result wouldbe the formation of a polyurea which normally would be insoluble in thereaction product and would separate as a solid either immediately or onstanding.

This is indeed what is found to happen when the reaction between theacid phosphate (I) or (II) is reacted with the organic polyisocyanate atany temperature below about 60° C. If the reaction is carried out abovesaid temperature but below about 190° C., it is found that it ispossible to obtain a product which, on cooling to ambient temperature(circa 15°-25° C.) and maintaining thereat even for prolonged periods,does not deposit solid material. However, the reaction temperature isnot the only important factor. It is found that the time for whichheating is carried out is important and, in general, the higher thereaction temperature, the shorter the period for which the heating canbe carried out without consequences which are fatal to the storagestability of the reaction product. Illustratively, even when thereaction temperature is as low as about 60° C., it is found that thereis a limited time beyond which further heating causes transformation ofthe pyrophosphates into what are believed to be higher polyphosphates.When the proportion of the latter in the reaction product reaches asufficiently high level it is found that, on subsequent cooling of thereaction product, the polyphosphates separate generally as a liquidlayer immiscible with the polyisocyanate. Further, the higher thereaction temperature, the shorter the period for which the reaction ofacid phosphate and polyisocyanate can be allowed to continue without theonset of the above described transformation of the pyrophosphates.

The exact chemical composition of the products which separate, eitherwhen operating at a temperature less than the minimum set forth above orwhen heating for a period longer than that which will give rise to ahomogeneous liquid product, it not known precisely and is not importantto an understanding of the invention. The above discussion has beenoffered by way of explanation only and it is to be understood that thescope and import of the invention is not to be limited in any mannerwhatsoever by reason of the tentative identification of the by-productsset forth above.

The time for which the process of the invention can be carried out atany given temperature within the range set forth above can varyaccording to the particular acid phosphate and polyisocyanate which areemployed. The appropriate time in any given instance can be determinedreadily by a process of trial and error. In general, the reaction timeswhich can be employed without giving rise to products which show phaseseparation on cooling vary from several hours at about 60° C. down tothe order of a minute or less at the higher end of the temperaturerange. As set forth above, the higher the temperature employed, theshorter the reaction time which can be employed without deleteriousresults.

The manner in which the acid phosphate and the organic polyisocyanateare brought together can also, in certain cases, affect the ability toproduce a storage stable composition in accordance with the invention.It is possible in many instances to bring the two reactants together, inany conventional manner, at ambient temperature and then to heat theresulting mixture at a temperature within the range set forth for a timewhich has been determined to give the desired result at the particularreaction temperature chosen. However, it is preferred to preheat thepolyisocyanate to the selected reaction temperature and then to add theacid phosphate to the preheated polyisocyanate. When operating a batchtype procedure, the addition can be carried out in a single charge orcan be carried out slowly over a period of time.

The process of the invention can also be carried out in a continuousmanner in which the mixture of polyisocyanate (preferably preheated) andacid phosphate is passed through a heating zone maintained at atemperature within the range set forth above. The rate of flow ofmixture through the heating zone is adjusted so that the residence timein the mixing zone corresponds to the selected reaction time. A widevariety of conventional apparatus can be employed for this purpose.Particularly useful apparatus is that of the type in which the mixtureto be heated is spread in the form of a thin film over the walls of theheating vessel. A typical example of such apparatus is that set forth inU.S. Pat. No. 2,927,634. In another embodiment the polyisocyanate(preferably preheated) and the acid phosphate are charged continuously,in the appropriate proportions, to a stirred reactor in which thecontents are maintained at the desired temperature. Reaction mixture iswithdrawn from the reactor at the same rate as the fresh reactants areadded and the rate of addition and withdrawal are such that theresidence time of the mixture in the reactor corresponds to the selectedreaction time.

Whether the process of the invention is carried out in a batch orcontinuous manner, it is desirable that the reaction be carried out inthe absence of oxygen and moisture, i.e. in the presence of an inert gassuch as nitrogen in accordance with the usual practice of handlingpolyisocyanates.

The proportions in which the polyisocyanate and the acid phosphates (I)and or (II) are employed in the process of the invention can vary over awide range but advantageously the acid phosphate is employed in anamount corresponding to about 1 to about 20 parts by weight per 100parts by weight of polyisocyanate. In a preferred embodiment the amountof acid phosphate employed is such that the polyisocyanate compositionsproduced in accordance with the invention contain from about 0.1 toabout 3 percent by weight of phosphorus.

The polyisocyanates employed in the process of the invention can be anyorganic polyisocyanate which contains at least two isocyanate groups permolecule. Illustrative of organic polyisocyanates are diphenylmethanediisocyanate, m- and p-phenylene diisocyanates, chlorophenylenediisocyanate, α,α'-xylylene diisocyanate, 2,4- and 2,6-toluenediisocyanate and the mixtures of these latter two isomers which areavailable commercially, triphenylmethane triisocyanates,4,4═-diisocyanatodiphenyl ether, and polymethylene polyphenylpolyisocyanates. The latter polyisocyanates are mixtures containing fromabout 25 to about 90 percent by weight of methylenebis(phenylisocyanate) the remainder of the mixture being polymethylene polyphenylpolyisocyanates of functionality higher than 2.0. Such polyisocyanatesand methods for their preparation are well-known in the art; see, forexample, U.S. Pat. Nos. 2,683,730; 2,950,263; 3,012,008 and 3,097,191.

These latter polyisocyanates are also available in various modifiedforms. One such form comprises a polymethylene polyphenyl polyisocyanateas above which has been subjected to heat treatment, generally attemperatures from about 150° C. to about 300° C., until the viscosity(at 25° C.) has been increased to a value within the range of about 800to 1500 centipoises. Another modified polymethylene polyphenylpolyisocyanate is one which has been treated with minor amounts of anepoxide to reduce the acidity thereof in accordance with U.S. Pat. No.3,793,362. The polymethylene polyphenyl polyisocyanates can also beemployed in the form of prepolymers and quasi-prepolymers, i.e. theproducts obtained by reacting the polyisocyanate with a minor amount ofa polyol, as well as in the form of polyisocyanates which have beenpartially blocked by reaction with a monohydric alcohol using procedureswell-known in the art.

The polymethylene polyphenyl polyisocyanates are the preferredpolyisocyanates for use in the process and compositions of theinvention. Particularly preferred polymethylene polyphenylpolyisocyanates are those which contain from about 35 to about 65percent by weight of methylenebis(phenyl isocyanate).

While any of the acid phosphates of formulae (I) and (II) can beemployed in the process of the invention, those acid phosphates whereinR represents alkyl or alkenyl and X represents O, and more particularly,those acid phosphates wherein R represents alkyl or alkenyl having from8 to 18 carbon atoms and X represents O, exhibit advantages because ofready availability and low cost.

The liquid, storage-stable, polyisocyanate compositions prepared inaccordance with the process of this invention are particularly useful asbinder resins for use in the preparation of particle boards inaccordance with methods well-known in the art; see supra. Thecompositions of this invention possess the advantage of preventingadherence of the particle board to the caul plates of the press used inthe preparation of the latter. For this particular use, i.e. as binderresins for particle board, it is desirable (but not essential) that thepolyisocyanate compositions of the invention have a viscosity in therange of about 100 to about 3000 cps. to facilitate ease of handling inthe equipment currently employed in the manufacture of particle board.Viscosities in the above range can be attained readily when employingpolymethylene polyphenyl polyisocyanates having an initial viscosity ofthe order of about 25 cps. to about 1000 cps. and subjecting thesepolyisocyanates to the process of the invention. This represents anadditional reason for employing such polyisocyanates in a preferredembodiment of the invention.

Where the polyisocyanate compositions of the invention are to beemployed as binder resins in the preparation of particle boards and thelike it is frequently the case that the polyisocyanate composition willbe applied to the particle board chips, prior to heating and pressing ofthe latter, in the form of an aqueous emulsion or dispersion. In orderto facilitate the formation of the latter it is desirable to employ anemulsifying or dispersing agent. If desired, the latter agent can beincorporated into the polyisocyanate compositions of the invention so asto enable the particle board manufacturer to prepare the requiredemulsion or dispersion without the need to employ additional agents.Accordingly, in an optional embodiment of the invention, thepolyisocyanate compositions of the invention can have incorporatedtherein an emulsifying or dispersing agent. The latter can be any ofthose known in the art including anionic and nonionic emulsifying anddispersing agents. Illustrative of such agents are polyoxyethylene andpolyoxypropylene alcohols and block copolymers of two or more ofethylene oxide, propylene oxide, butylene oxide, and styrene;alkoxylated alkylphenols such as nonylphenoxypoly(ethyleneoxy)ethanols;alkoxylated aliphatic alcohols such as ethoxylated and propoxylatedaliphatic alcohols containing from about 4 to 18 carbon atoms;glycerides of saturated and unsaturated fatty acids such as stearic,oleic, and ricinoleic acids and the like; polyoxyalkylene esters offatty acids such as stearic, lauric, oleic and like acids; fatty acidamides such as the dialkanolamides of fatty acids such as stearic,lauric, oleic and like acids. A detailed account of such materials isfound in Encyclopedia of Chemical Technology, Second Edition, Vol. 19,pp. 531-554, 1969, Interscience Publishers, New York.

The acid phosphates of the formulae (I) and (II) are, for the most part,well-known in the art, and can be prepared by methods well-known in theart. Illustratively, the acid phosphates (I) and (II) are obtained byreaction of the corresponding alcohol or thiol R--XH, wherein R and Xare as hereinbefore defined, with phosphorus pentoxide or phosphorusoxysulfide using the procedures described by Kosolapoff,Organophosphorus Compounds, pp. 220-221, John Wiley and Sons, Inc., NewYork, 1950. This reaction gives rise to a mixture of the mono- anddi-acid phosphate which mixture can be separated, if desired, forexample by fractional crystallization of the barium and like salts asdescribed in the above cited reference. The individual acid phosphates,or the mixture of the mono- and di-acid phosphates obtained inaccordance with the above reaction, can be employed as startingmaterials in the process of the invention.

The following examples describe the manner and process of making andusing the invention and set forth the best mode contemplated by theinventors of carrying out the invention but are not to be construed aslimiting.

EXAMPLE 1

A series of reactions were carried out using as the acid phosphate amixture of mono- and di-lauryl acid phosphate (Tryfac 5573: EmeryIndustries) and as the polyisocyanate a polymethylene polyphenylpolyisocyanate containing approximately 46.5 percent by weight ofmethylenebis (phenyl isocyanate) and having an isocyanate equivalent of134.5 and a viscosity of 25° C. of 173 cps. In each instance 100 partsby weight of the polyisocyanate was heated to a preselected temperatureand 7 parts by weight of the acid phosphate was added dropwise over aperiod of 30 minutes. The resulting mixture was then maintained at thepreselected temperature for a preselected period (see Table I below) andwas then cooled rapidly to room temperature (circa 20° C.) andmaintained thereat for several months. The reaction conditions andresults are summarized in Table I from which it will be seen that thesamples prepared using reaction temperatures of 60° and 100° C. for aperiod of two hours were not storage stable, whereas the other samplesremained liquid for the duration of the storage test without showing anyseparation of phases. The sample made at 100° C. became turbid oncooling and separated into the two liquid phases within a very shorttime thereafter.

                  TABLE I                                                         ______________________________________                                                                   Initial                                                                       Viscosity                                                Reaction             of Product                                                                            Behaviour of                               Run   time     Reaction temp.                                                                            25° C. cstk.                                                                   Product                                    ______________________________________                                        1     2 hr.    60° C.                                                                             390     Solids deposited                           2     6 hr.    60° C.                                                                             337     Remained liquid                            3     2 hr.    80° C.                                                                             420     Remained liquid                            4     7.5 hr.  70° C.                                                                             530     Remained liquid                            5     4 hr.    100° C.                                                                            559     Formed 2 liquid                                                               phases                                     ______________________________________                                    

EXAMPLE 2

Using the same reactants and proportions as in Example 1 but employingin each instance a reaction temperature of 80° C., preheating thepolyisocyanate to that temperature and adding the acid phosphate theretoover a preselected period of time, a series of runs was carried out toillustrate the effect of reaction time on the properties of the reactionproduct. The reaction conditions and results are recorded in Table II.

                  TABLE II                                                        ______________________________________                                                         Reaction  Initial                                                  Addition time                                                                            time      Viscosity                                                                             Stability of                               Run   of phosphate                                                                             (hr.)     25° C. cstk.                                                                   Product                                    ______________________________________                                        6      2 minutes 2         418     Remains liquid                             7      5 seconds 3         401     Remains liquid                             8     15 minutes 5         477     Remains liquid                             9     15 minutes 6         610     Remains liquid                             10    15 minutes 23        776     separates: two                                                                liquid phases                              ______________________________________                                    

EXAMPLE 3

Using the procedure and the reactants set forth in Example 1 butemploying a reaction temperature of 100° C. and a reaction time of 15minutes, there was obtained a polyisocyanate composition which showed nosigns of phase separation after standing for several months at roomtemperature. This is in direct contrast to run 5 shown in TABLE I ofExample 1 which differed from the present run only in the longerreaction time of 4 hours.

EXAMPLE 4

A series of three runs was carried out using as the polyisocyanate apolymethylene polyphenyl polyisocyanate containing approximately 31percent by weight of methylenebis(phenyl isocyanate) and having anisocyanate equivalent of 139 and a viscosity at 25° C. of 700 cps. Ineach run the polyisocyanate (100 parts by weight) was preheated to 80°C. and the lauryl acid phosphate (same as Example 1; amount used isshown in TABLE III) was added thereto over a period of 10 minutes andthe mixture was then heated at 80° C. for the time shown in Table III.Each of the three products so obtained was a liquid which showed notendency to separate into two phases on standing for several months.

                  TABLE III                                                       ______________________________________                                              Parts by wt. of                                                                           Reaction time                                                                              Initial Viscosity of                           Run   phosphate   (hr.)        product 25° C. cstk.                    ______________________________________                                        11    5           1.5           890                                           12    7           2            1717                                           13    10          2            (N.T.)                                         ______________________________________                                    

EXAMPLE 5

A series of runs was carried out using the same polyisocyanate as thatdescribed in Example 1 but using a variety of different acid phosphates,each of which was employed in an amount which gave a final productcontaining 0.57 percent by weight of phosphorus. In each run thepolyisocyanate was preheated to 80° C. and the acid phosphate was addedthereto with stirring over a period of 15 minutes. The resulting mixturewas heated at 80° C. for 2 hours before being cooled to ambienttemperature (circa 20° C.). The product obtained in each case was aliquid which showed no signs of phase separation on being stored atambient temperature for several months. The identity of the various acidphosphates used, the amount used, and the initial viscosity of thereaction product are recorded in TABLE IV.

                  TABLE IV                                                        ______________________________________                                                                         Initial Viscosity                                                Wt. % of     Product                                      Run   Acid phosphate                                                                              acid phosphate                                                                             25° cstk.                             ______________________________________                                        14    Tryfac 610A.sup.1                                                                           14.3         682                                          15    Tryfac 525A.sup.2                                                                           13.6         1018                                         16    Tryfac 325A.sup.3                                                                           10.6         530                                          17    Fosterge A2523.sup.4                                                                        9.7          395                                          18    Fosterge R.sup.5                                                                            4.6          350                                          19    Textilana.sup.6                                                                             6.9          412                                          ______________________________________                                         Footnotes:                                                                    .sup.1 Mixture of mono and didecylpolyoxyethylene acid phosphates: Emery      Industries.                                                                   .sup.2 Mixture of mono and didodecylpolyoxyethylene acid phosphates: Emer     Industries.                                                                   .sup.3 Mixture of mono and didodecylpolyoxyethylene acid phosphates: Emer     Industries.                                                                   .sup.4 Mixture of mono and didodecylpolyoxyethylene acid phosphates:          Textilana Division of Henkel Inc., Hawthorne, California.                     .sup.5 Mixture of mono and dioctyl acid phosphates: Textilana, ibid.          .sup.6 Mixture of mono and ditridecyl acid phosphates: Textilana, ibid.  

We claim:
 1. A process for preparing a .[.liquid, storage-stable,polyisocyanate composition containing a mold release agent formed insitu which process comprises.]. .Iadd.particle board wherein particlesof organic material capable of being compacted are contacted with apolyisocyanate binder composition containing an internal release agentand the treated particles are subsequently formed into boards by theapplication of heat and pressure, the process being characterized inthat the polyisocyanate binder composition has been prepared by.Iaddend.heating at a temperature in the range of about 60° C. to about190° C. a mixture of an organic polyisocyanate and from about 1 to about20 parts, per 100 parts by weight of said polyisocyanate, of an acidphosphate selected from the class consisting of acid phosphates havingthe formulae ##STR4## and mixtures of two or more of said acidphosphates wherein, in the above formulae, each R is independentlyselected from the class consisting of alkyl having at least 3 carbonatoms, alkenyl having at least 3 carbon atoms, aryl, aryl substituted byat least one alkyl group, alkyl substituted by at least one acyloxygroup wherein the acyl group is the residue of an aliphaticmonocarboxylic acid having at least 2 carbon atoms and ##STR5## whereinR₁ is selected from the group consisting of alkyl, aryl and arylsubstituted by at least alkyl, one of A and B represents hydrogen andthe other is selected from the class consisting of hydrogen, methyl,chloromethyl and 2,2,2-trichloroethyl; X is a chalogen selected from theclass consisting of oxygen and sulfur; and m is a number having anaverage value of 1 to 25;the said heating of said mixture being carriedout for a time such that no phase separation occurs upon cooling thereaction mixture to ambient temperature.
 2. A process according to claim1 wherein the organic polyisocyanate is a mixture of polymethylenepolyphenyl polyisocyanates containing from about 25 to about 90 percentby weight of methylenebis(phenyl isocyanate), the remainder of saidmixture being oligomeric polymethylene polyphenyl polyisocyanates offunctionality greater than
 2. 3. A process according to claim 1 whereinthe acid phosphate is a mixture of mono- and di-alkyl acid phosphateswherein alkyl contains at least 3 carbon atoms.
 4. A process accordingto claim 1 wherein the acid phosphate is a mixture of mono- anddi-alkenyl acid phosphates wherein alkenyl contains at least 3 carbonatoms.
 5. A process according to claim 1 wherein the acid phosphate is amixture of mono- and di-alkylpolyoxyalkylene acid phosphates whereinalkylene is selected from the class consisting of ethylene andpropylene.
 6. A process according to claim 1 wherein the acid phosphateis a mixture of mono- and di-arylpolyoxyalkylene acid phosphates whereinalkylene is selected from the class consisting of ethylene and propyleneand said aryl group is unsubstituted or substituted by at least onealkyl group.
 7. A process for preparing a .[.liquid, storage-stable,polyisocyanate composition containing a mold release agent formed insitu which process comprises.]. .Iadd.particle board wherein particlesof organic material capable of being compacted are contacted with apolyisocyanate binder composition containing an internal release agentand the treated particles are subsequently formed into boards by theapplication of heat and pressure, the process being characterized inthat the polyisocyanate binder composition has been prepared by.Iaddend.heating, at a temperature in the range of about 60° C. to about190° C., a mixture of(a) a mixture of polymethylene polyphenylpolyisocyanates containing from about 25 to about 90 percent by weightof methylenebis(phenyl isocyanate), the remainder of said mixture beingoligomeric polymethylene polyphenyl polyisocyanates of functionalitygreater than 2; and (b) from about 1 to about 20 parts, per 100 parts byweight of polyisocyanate, of an acid phosphate selected from the classconsisting of acid phosphates having the formulae ##STR6## and mixturesof two or more of said acid phosphates; wherein, in the above formulae,each R is independently selected from the class consisting of alkylhaving at least 3 carbon atoms, alkenyl having at least 3 carbon atoms,aryl, aryl substituted by at least one alkyl group, alkyl substituted byat least one acyloxy group wherein the acyl group is the residue of analiphatic monocarboxylic acid having at least 2 carbon atoms and##STR7## wherein R₁ is selected from the group consisting of alkyl, aryland aryl substituted by at least one alkyl, one of A and B representshydrogen and the other is selected from the class consisting ofhydrogen, methyl, chloromethyl and 2,2,2-trichloroethyl; X is achalcogen selected from the class consisting of oxygen and sulfur; and mis a number having an average value of 1 to 25; the said heating of saidmixture being carried out for a time such that no phase separationoccurs upon cooling the reaction mixture to ambient temperature.
 8. Aprocess according to claim 7 in which the polyisocyanate is preheated toa temperature within the stated range and the acid phosphate is admixedwith the said preheated polyisocyanate.
 9. A process according to claim7 or 8 in which the acid phosphate is a mixture of mono- and di-alkylacid phosphates wherein alkyl contains at least 3 carbon atoms.
 10. Aprocess according to claim 9 wherein said mixture of mono- and di-alkylacid phosphates is a mixture of lauryl monoacid phosphate and dilaurylacid phosphate.
 11. A process according to claim 7 or 8 in which theacid phosphate is a mixture of mono- and di-alkenyl acid phosphateswherein alkenyl contains at least 3 carbon atoms.
 12. A processaccording to claim 7 or 8 in which the acid phosphate is a mixture ofmono- and di-alkylpolyoxyalkylene acid phosphates wherein alkylene isselected from the class consisting of ethylene and propylene.
 13. Aprocess according to claim 7 or 8 in which the acid phosphate is amixture of mono- and di-aryl polyoxyalkylene acid phosphates whereinalkylene is selected from the class consisting of ethylene and propyleneand said aryl group is unsubstituted or substituted by at least onealkyl group. .[.14. A liquid, storage-stable, polyisocyanate compositionprepared in accordance with claim 1..]. .[.15. A liquid, storage-stable,polyisocyanate composition prepared in accordance with claim 7..].